Encapsulated labile compound compositions and methods of making the same

ABSTRACT

Products comprising labile compounds, such as polyunsaturated fatty acids, and having first and second encapsulants are disclosed. A first encapsulant can be a spray dried coating and the second encapsulant can be a prill coating. Methods of making the same are provided.

CROSS-REFERENCE TO RELATED TO RELATED APPLICATIONS

This application claims benefit under 35 U.S.C. §119(e) of U.S.Provisional Application No. 60/805,590, filed Jun. 22, 2006 and U.S.Provisional Application No. 60/945,040 filed Jun. 19, 2007. Thedisclosure of each of these application is incorporated by referenceherein in its entirety.

FIELD OF THE INVENTION

The invention relates to encapsulated labile compounds, includingpolyunsaturated fatty acids, and methods of making the same.

BACKGROUND OF THE INVENTION

Labile compounds and compositions, such as polyunsaturated fatty acids(PUFAs), vitamins, minerals, antioxidants, hormones, amino acids,proteins, carbohydrates, coenzymes, and flavor agents, sensitive to anynumber of factors, can lose biological or other desired activity whenunprotected. In addition, products (for example, decomposition products,degradation products, and oxidation products) that result from thechemical, physical, or biological change or breakdown of labilecompounds and compositions, could lack the desired biological functionand/or possess unwanted characteristics, such as having off-flavors,undesirable odors, irritation promoting activity and the like. There isoften a need to introduce labile compounds and compositions, which aresusceptible to chemical, physical, or biological change or breakdown,into pharmaceutical, nutritional, including nutraceutical, andindustrial products. In such instances, protection of such compounds andcompositions is desirable. With regard to PUFAs in particular, it isdesirable to protect such lipids in food products from oxygen, tracemetals and other substances which attack the double bonds of the PUFAs.Such protection reduces the likelihood of organoleptic problems, i.e.,problems, relating to the senses (taste, color, odor, feel), such asoff-flavors and undesirable odors, and other problems, such as loss ofphysiological activity, for instance. Such protection could potentiallyincrease the shelf life of products containing them.

Encapsulating unstable compounds can protect them from undesirablechemical, physical, or biological change or breakdown while retainingtheir efficacy, such as biological or physiological efficacy.Microcapsules can exist in powdered form and comprise roughly sphericalparticles that contain an encapsulated (entrapped) substance. Theparticle usually has some type of shell, often a polymeric shell, suchas a polypeptide or polysaccharide shell, and the encapsulated activeproduct is located within the shell. Microencapsulation of a liquid,such as an oil, allows the formation of a particle that presents a dryouter surface with an entrained oil. Often the particles are afree-flowing powder. Microencapsulation therefore effectively enablesthe conversion of liquids to powders. Numerous techniques formicroencapsulation are known depending on the nature of the encapsulatedsubstance and on the type of shell material used. Methods typicallyinvolve solidifying emulsified liquid droplets by changing temperature,evaporating solvent, or adding chemical cross-linking agents. Suchmethods include, for example, spray drying, interfacial polymerization,hot melt encapsulation, phase separation encapsulation (solvent removaland solvent evaporation), spontaneous emulsion, solvent evaporationmicroencapsulation, solvent removal microencapsulation, coacervation,and low temperature microsphere formation and phase inversionnanoencapsulation (PIN). Microencapsulation is suitable for drugs,vitamins and food supplements since this process is adaptable by varyingthe encapsulation ingredients and conditions.

There is a particular need to provide microencapsulated forms of fats oroils, such as vegetable and marine oils, which contain PUFAs. Suchmicroencapsulated forms would benefit from the properties ofdigestibility, stability, resistance to chemical, physical, orbiological change or breakdown. Microencapsulated oils couldconveniently be provided as a free flowing powdered form. Such a powdercan be readily mixed with other dry or liquid components to form auseful product.

The ability to microencapsulate, however, can be limited by factors dueto the nature of the microencapsulation process or the compound orcomposition to be encapsulated. Such factors could include pH,temperature, uniformity, viscosity, hydrophobicity, molecular weight,and the like. Additionally, a given microencapsulation process may haveinherent limitations. For example, in microencapsulation techniques inwhich heat is used for drying, low-boiling point aromatics can be lostduring the drying process. Additionally, the core may adhere to thesurface of the encapsulation material, presenting a potential forincreased oxidation and changes in the flavor balance of the finishedproduct. In some cases, storage conditions must be carefully controlledto avoid an increase in the water activity and therefore the stabilityof the capsule and retention of volatiles within the capsule. Duringspray drying microencapsulation, the feed inlet temperature may not behigh enough and result in incomplete drying and sticking in the dryingchamber or clump formation in storage. Particulate inconsistencies mayalso occur under some process conditions. At temperatures that are toolow, the particles may balloon and cracks can form in the surface of theparticles. This may cause loss of volatile compounds and compromise thequality of the final product. Yet another drawback is that the coatingsproduced are often water-soluble and temperature sensitive. The presentinventors have recognized the foregoing problems and that there is aneed, therefore, to provide additional processes for encapsulation ofcompounds and compositions susceptible to chemical, physical, orbiological change or breakdown.

SUMMARY OF THE INVENTION

The present invention is directed to products comprising labilecompounds, such as polyunsaturated fatty acids, and having first andsecond encapsulants, as well as methods of making the same.

In one embodiment, the invention provides a product comprising acomposition comprising a labile compound; a first encapsulant of thecomposition; and a second encapsulant of the first encapsulant, whereinthe second encapsulant is a prill coating, wherein the product furthercomprises a Maillard reaction product.

The invention also provides a product comprising a compositioncomprising a labile compound; a first encapsulant of the composition;and a second encapsulant of the first encapsulant, wherein the productfurther comprises a Maillard reaction product formed by contacting thefirst encapsulant with the second encapsulant.

The invention further provides a product comprising a compositioncomprising a labile compound; a first encapsulant of the composition;and a second encapsulant of the first encapsulant, wherein the secondencapsulant further comprises a Maillard reaction product.

The invention also provides a product comprising a compositioncomprising a labile compound; a first encapsulant of the composition;and a second encapsulant of the first encapsulant, wherein the productfurther comprises a Maillard reaction product formed in a non-aqueousenvironment.

The labile compound includes polyunsaturated fatty acid, a vitamin, amineral, an antioxidant, a hormone, an amino acid, a protein, acarbohydrate, a coenzyme, a flavor agent, and mixtures of the foregoing.

The invention also provides a product comprising a compositioncomprising a labile compound selected from the group consisting of apolyunsaturated fatty acid, a vitamin, a mineral, an antioxidant, ahormone, an amino acid, a protein, a carbohydrate, a coenzyme, andmixtures thereof; a first encapsulant of the composition; and a prillcoating on the first encapsulant.

In some embodiments, the labile compound comprises a polyunsaturatedfatty acid from a source selected from the group consisting of a plant,an oilseed, a microorganism, an animal, and mixtures of the foregoing.In some embodiments, the microorganism includes algae, bacteria, fungiand protists.

In some embodiments, the source is selected from the group consisting ofplant and oilseed selected from the group consisting of soybean, corn,safflower, sunflower, canola, flax, peanut, mustard, rapeseed, chickpea,cotton, lentil, white clover, olive, palm, borage, evening primrose,linseed and tobacco and mixtures thereof.

In some embodiments, the source includes a genetically modified plant, agenetically modified oilseed, and a genetically modified microorganism,wherein the genetic modification comprises the introduction ofpolyketide synthase genes.

In other embodiments, the microorganism includes Thraustochytriales,dinoflagellates, and Mortierella. In still other embodiments, themicroorganism includes Schizochytrium, Thraustochytrium or adinoflagellate of the genus Crypthecodinium.

In some embodiments, the animal includes an aquatic animal.

In some embodiments, the labile compound comprises a polyunsaturatedfatty acid having a chain length of at least 18 carbons. In otherembodiments, the labile compound comprises a polyunsaturated fatty acidincluding docosahexaenoic acid, omega-3 docosapentaenoic acid, omega-6docosapentaenoic acid, arachidonic acid, eicosapentaneoic acid,stearidonic acid, linolenic acid, alpha linolenic acid (ALA), gammalinolenic acid (GLA), conjugated linolenic acid (CLA) and mixturesthereof.

In other embodiments, the labile compound comprises a vitamin selectedfrom the group consisting of Vitamin A, Vitamin D, Vitamin E, Vitamin K,Vitamin B1, Vitamin B2, Vitamin B3, Vitamin B6, Vitamin C, Folic Acid,Vitamin B-12, Biotin, Vitamin B5 and mixtures thereof.

In other embodiments, the labile compound comprises a mineral selectedfrom the group consisting of calcium, iron, iodine, magnesium, zinc,selenium, copper, manganese, chromium, molybdenum and mixtures thereof.

In still other embodiments, the labile compound comprises an antioxidantselected from the group consisting of lycopene, lutein, zeaxanthin,alpha-lipoic acid, coenzymeQ, beta-carotene and mixtures thereof.

In further embodiments, the labile compound comprises an amino acidselected from the group consisting of arginine, aspartic acid,carnitine, cysteine, glutamic acid, glutamine, glycine, histidine,isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine,threonine, tryptophan, tyrosine, valine, SAM-e and mixtures thereof.

In some embodiments in which the labile compound is a flavor agent, theflavor agent comprises a flavor oil, oleoresin or mixtures thereof.

In some embodiments, the first encapsulant of the composition comprisingthe labile compound includes a whole cell, a biomass hydrolysate, anoilseed and an encapsulated isolated labile compound.

In other embodiments, the first encapsulant of the compositioncomprising the labile compound is a whole cell or a biomass hydrolysatederived from microorganisms. The microorganism includes Lactococcuslactis, Lactobacillus acidophilus, Lactobacillus crispatus,Lactobacillus amylovorous, Lactobacillus gallinarum, Lactobacillusgasseri, Lactobacillus johnsonii, Lactobacillus rhamnosus, Lactobacillusbrevis, Lactobacillus fermentum, Lactobacillus plantarum, Lactobacillushelveticus, Lactobacillus casei, Lactobacillus delbruckii, Lactobacillusbulgaricus, Lactobacillus plantarum, Lactobacillus GG, Bifidobacteriumbifidum, Bifidobacterium breve, Bifidobacteriun infantis,Bifidobacterium longum, Streptococcus thermophilus and Leuconostocmesenteroides.

In some embodiments, the first encapsulant of the composition comprisingthe labile compound is a dried whole cell. In some embodiments, thedried whole cell is a spray-dried whole cell.

In some embodiments, the first encapsulant is prepared by a method isselected from the group consisting of fluid bed drying, drum (film)drying, coacervation, interfacial polymerization, fluid bed processing,pan coating, spray gelation, ribbon blending, spinning disk, centrifugalcoextrusion, inclusion complexation, emulsion stabilization, spraycoating, extrusion, liposome nanoencapsulation, supercritical fluidmicroencapsulation, suspension polymerization, cold dehydrationprocesses, spray chilling (prilling), and evaporative dispersionprocesses.

In some embodiments, the prill coating is selected from the groupconsisting of a fatty acid monoglyceride; a fatty acid diglyceride; afatty acid triglyceride; a free fatty acid; tallow; lard; beeswax;lanolin; shell wax; insect wax; vegetable wax, carnauba wax; candelillawax; bayberry wax; sugar cane wax; mineral wax; paraffinmicrocrystalline petroleum wax; ozocerite wax; ceresin wax; montansynthetic wax, low molecular weight polyolefin; polyol ether-esters,sorbitol; Fischer-Tropsch process synthetic wax; rosin; balsam; shellac;stearylamide; ethylenebisstearylamide; hydrogenated castor oil; estersof pentaerythritol; mono and tetra esters of stearic acid; vegetableoil; a hydrogenated vegetable oil; and mixtures and derivatives of theforegoing.

In certain embodiments, the prill coating is a free fatty acid selectedfrom the group consisting of stearic acid, palmitic acid, and oleicacid.

In embodiments in which the prill coating is tallow, the tallow includesbeef tallow, mutton tallow, pork tallow, and lamb tallow.

In embodiments in which the prill coating is hydrogenated vegetable oil,the hydrogenated vegetable oil includes hydrogenated cottonseed oil,hydrogenated sunflower oil, hydrogenated safflower oil, hydrogenatedsoybean oil, hydrogenated corn oil, hydrogenated olive oil, hydrogenatedcanola oil, hydrogenated linseed oil, hydrogenated flaxseed oil.

In some embodiments, the prill coating further comprises a fat-solubleor fat dispersible oxygen scavenger, or a fat-soluble or fat dispersibleantioxidant.

In some embodiments, the prill coating further comprises a colorant.

In some embodiments, the Maillard reaction product includes a reactionproduct of a reducing sugar and a protein selected from the groupconsisting of casein, whey solids, whey protein isolate, soy protein,skim milk powder, hydrolyzed casein, hydrolyzed whey protein, hydrolyzedsoy protein, non-fat milk solids, gelatin, zein, and albumin.

In some embodiments, the Maillard reaction product includes a reactionproduct of a protein and a reducing sugar selected from the groupconsisting of fructose, glucose, glyceraldehyde, lactose, arabinose,maltodextrin, corn syrup solids and maltose.

The invention also provides a product selected from the group consistingof a food product, a cosmetic product, a pharmaceutical product, anutraceutical product, and an industrial product, in which the productcomprises a product comprising a composition comprising a labilecompound; a first encapsulant of the composition; and a secondencapsulant of the first encapsulant, wherein the second encapsulant isa prill coating, wherein the product further comprises a Maillardreaction product.

In some embodiments, the food product includes liquid food products orsolid food products. Liquid food products include beverages, infantformula, liquid meals, liquid eggs, milk products, and multivitaminsyrups. Beverages include energy drinks, fruit juices, and milk. Solidfood products include baby food, yogurt, cheese, cereal, powdered mixes,baked goods, food bars, and processed meats.

In some embodiments, the product is insoluble in water. In otherembodiments the product is physically stable for at least about 30 days,or oxidatively stable for at least about 30 days.

In other embodiments, the Maillard reaction product provides a desirableflavor to the product, a desirable aroma to the product, or antioxidantprotection to the product.

In some embodiments, the Maillard reaction product is present in theouter 75% of the second encapsulant.

In some embodiments, the product has a particle size of between about 10μm and about 3000 μm.

In further embodiments, the product comprises labile compound in anamount between about 1 weight percent and about 50 weight percent.

In still further embodiments, the product is in a form selected from thegroup consisting of a free-flowing powder, a bead, a chip, and a flake.

The invention also provides a method for preparing a product comprisingencapsulating a first encapsulated product in the presence of an aminoacid source and a reducing sugar to form a second encapsulated product,whereby Maillard reaction products are formed, and wherein the firstencapsulated product comprises an encapsulant of a labile compound.

In some embodiments, the method further comprises handling the labilecompound under conditions that reduce oxidative degradation prior toencapsulation.

In some embodiments of the method, the first encapsulated productcomprises the amino acid source and the reducing sugar.

In other embodiments, the method further comprising processing thesecond encapsulated product into a particulate form. The processingincludes fluid bed drying, drum (film) drying, coacervation, interfacialpolymerization, fluid bed processing, pan coating, spray gelation,ribbon blending, spinning disk, centrifugal coextrusion, inclusioncomplexation, emulsion stabilization, spray coating, extrusion, liposomenanoencapsulation, supercritical fluid microencapsulation, suspensionpolymerization, cold dehydration processes, spray chilling (prilling),and evaporative dispersion processes.

In further embodiments, the step of encapsulating the first encapsulatedproduct is conducted at a temperature above about 85° C.

In some embodiments, the step of encapsulating the first encapsulatedproduct is conducted for between about 1 minute and about 15 minutes.

In other embodiments, the first encapsulated product is formed by amethod comprising emulsifying an aqueous dispersion of a polyunsaturatedfatty acid, protein and reducing sugar to form an emulsion; and dryingthe emulsion to form the first encapsulated product.

In further embodiments, the encapsulating the first encapsulated productcomprises contacting the first encapsulated product with a prillingmaterial, spraying the mixture of the first encapsulated product withthe prilling material into droplets, and cooling the droplets below themelting point of the prilling material to form the second encapsulatedproduct. In some embodiments, the prilling material has a melting pointin the range of about 32° C. to about 122° C.

In other embodiments, the step of contacting the first encapsulatedproduct with the prilling material is conducted at a temperature aboveabout 85° C.

In still other embodiments, the step of contacting the firstencapsulated product with the prilling material is conducted for betweenabout 1 minute and about 15 minutes.

In further embodiments, the prilling material is hydrogenated vegetableoil, and the step of contacting the first encapsulated product with theprilling material is conducted for between about 1 minute and about 15minutes, between 80° C. and 100° C.

In some embodiments, the first encapsulated product comprises about 25wt % to about 80 wt % labile compound; about 5 wt % to about 25 wt % ofan amino acid source; and about 15 wt % to about 70 wt % of a reducingsugar.

In other embodiments, the second encapsulated product is in particulateform and wherein the particulates comprise more than one coatedencapsulated product per particulate.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the improvement in the induction period for a product ofthe invention (dark grey bars) when compared to a singly encapsulatedproduct (light grey bars).

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides encapsulated labile compounds and relatedmethods for their preparation. In various embodiments, the inventionprovides a product comprising a composition comprising a labilecompound, a first encapsulant of the composition, and a secondencapsulant of the first encapsulant, and in some embodiments, thesecond encapsulant can be a prill coating. In some embodiments, theproduct further comprises a Maillard reaction product (MRP). As usedherein, the term “a” or “an” refers to one or more of that entity; forexample, a PUFA refers to one or more PUFAs or at least one PUFA. Assuch, the terms “a” (or “an”), “one or more” and “at least one” can beused interchangeably herein. It is also to be noted that the terms“comprising”, “including”, and “having” can be used interchangeably.

In one embodiment, the invention is directed to a product that includesa composition comprising a labile compound with a first encapsulant ofthe composition and a prill coating on the first encapsulant. In thisembodiment, the product further comprises a Maillard reaction product.Reference to a prill coating or a second encapsulant being “on the firstencapsulant” refers to the prill coating or second encapsulant coatingor partially coating the first encapsulant and the composition having alabile compound. It will be recognized that the prill coating or thesecond encapsulant can either contact the first encapsulant directly orcan contact the first encapsulant through one or more intervening layersof other materials.

In one embodiment, the invention is directed to a product that includesa composition comprising a labile compound selected from the groupconsisting of a polyunsaturated fatty acid, a vitamin, a mineral, anantioxidant, a hormone, an amino acid, a protein, a carbohydrate, acoenzyme, and mixtures thereof. The product further includes a firstencapsulant of the composition and a prill coating on the firstencapsulant.

In another embodiment, the invention is directed to a product thatincludes a composition comprising a labile compound with a firstencapsulant of the composition and a second encapsulant of the firstencapsulant. In this embodiment, the product further comprises aMaillard reaction product formed by contacting the first encapsulantwith the second encapsulant.

In another embodiment, the invention is directed to a product thatincludes a composition comprising a labile compound with a firstencapsulant of the composition and a second encapsulant of the firstencapsulant. In this embodiment, the second encapsulant furthercomprises a Maillard reaction product.

In an additional embodiment, the invention is directed to a product thatincludes a composition comprising a labile compound with a firstencapsulant of the composition and a second encapsulant of the firstencapsulant. In this embodiment, the product further comprises aMaillard reaction product formed in a non-aqueous environment.

As used herein, a labile compound is a compound that will readilyundergo a chemical and/or biological change or breakdown; that is, acompound that undergoes a noticeable change under intended useconditions. E.g., a PUFA in a food product can undergo some degradationin palatability that is noticeable by a consumer of the food product.Such conditions can be defined in terms of temperature, storage time,presence of water, and the like. Labile compounds include, withoutlimitation, polyunsaturated fatty acids (PUFAs), vitamins, minerals,antioxidants, hormones, amino acids, proteins, carbohydrates, coenzymes,flavor agents and mixtures of the foregoing. In a further embodiment,the labile compound can be selected from PUFAs, vitamins, minerals,antioxidants, hormones, amino acids, proteins, carbohydrates, coenzymes,and mixtures thereof. The labile compound can be in the form of a solidparticle, a liquid droplet, a gas bubble, or mixtures of these. In onepreferred embodiment, the labile compound is a solid particle, and inanother preferred embodiment, the labile compound is a liquid.

In some embodiments of the invention, the labile compound is a PUFA. Insome embodiments, a PUFA has a chain length of at least 18 carbons. SuchPUFAs are referred to herein as long chain PUFAs or LC PUFAs. In someembodiments, the PUFA can be docosahexaenoic acid C22:6(n-3) (DHA),omega-3 docosapentaenoic acid C22:5(n-3) (DPA(n-3)), omega-6docosapentaenoic acid C22:5(n-6) (DPA(n-6)), arachidonic acid C20:4(n-6)(ARA), eicosapentaenoic acid C20:5(n-3) (EPA), stearidonic acid,linolenic acid, alpha linolenic acid (ALA), gamma linolenic acid (GLA),conjugated linolenic acid (CLA) or mixtures thereof. The PUFAs can be inany of the common forms found in natural lipids including but notlimited to triacylglycerols, diacylglycerols, monoacylglycerols,phospholipids, free fatty acids, or in natural or synthetic derivativeforms of these fatty acids (e.g. calcium salts of fatty acids, esters offatty acids, including methyl esters, ethyl esters, and the like).Reference to an oil or other composition comprising an LC PUFA, as usedin the present invention, can refer to either a composition comprisingonly a single LC PUFA such as DHA or a composition comprising a mixtureof LC PUFAs such as DHA and EPA, or DHA and ARA.

While certain embodiments are described herein with reference to PUFAsfor the sake of convenience and conciseness, it is to be understood thatproducts comprising other labile compounds are included within the scopeof the invention. PUFAs can be obtained from or derived from a plant(including oilseeds; as one skilled in the art will appreciate, anoilseed is part of a plant), a microorganism, an animal, or mixtures ofthe foregoing. The microorganisms can be algae, bacteria, fungi orprotists. Microbial sources and methods for growing microorganismscomprising nutrients and/or PUFAs are known in the art (IndustrialMicrobiology and Biotechnology, 2nd edition, 1999, American Society forMicrobiology). For example, the microorganisms can be cultured in afermentation medium in a fermentor. PUFAs produced by microorganisms canbe used in the methods and compositions of the present invention. Insome embodiments, organisms include those selected from the groupconsisting of golden algae (such as microorganisms of the kingdomStramenopiles), green algae, diatoms, dinoflagellates (such asmicroorganisms of the order Dinophyceae including members of the genusCrypthecodinium such as, for example, Crypthecodinium cohnii), yeast,and fungi of the genera Mucor and Mortierella, including but not limitedto Mortierella alpina and Mortierella sect. schinuckeri. Members of themicrobial group Stramenopiles include microalgae and algae-likemicroorganisms, including the following groups of microorganisms:Hamatores, Proteromonads, Opalines, Develpayella, Diplophrys,Labrinthulids, Thraustochytrids, Biosecids, Oomycetes,Hypochytridiomycetes, Commation, Reticulosphaera, Pelagomonas,Pelagococcus, Ollicola, Aureococcus, Parmales, Diatoms, Xanthophytes,Phaeophytes (brown algae), Eustigmatophytes, Raphidophytes, Synurids,Axodines (including Rhizochromulinaales, Pedinellales, Dictyochales),Chrysorneridales, Sarcinochrysidales, Hydrurales, Hibberdiales, andChromulinales. The Thraustochytrids include the genera Schizochytrium(species include aggregatum, limnaceum, mangrovei, minutum, octosporum),Thraustochytrium (species include arudimentale, aureum, benthicola,globosum, kinnei, motivum, multirudimentale, pachyderinum, proliferuin,roseum, striatum), Ulkenia (species include amoeboidea, kerguelensis,minuta, profunda, radiate, sailens, sarkariana, schizochytrops,visurgensis, yorkensis), Aplanochytrium (species include haliotidis,kerguelensis, profunda, stocchinoi), Japonochytrium (species includemarinum), Althornia (species include crouchii), and Elina (speciesinclude marisalba, sinorifica). The Labrinthulids include the generaLabyrinthula (species include algeriensis, coenocystis, chattonii,macrocystis, macrocystis atlantica, macrocystis macrocystis, mairina,minuta, roscoffensis, valkanovii, vitellina, vitellina pacifica,vitellina vitellina, zopfi), Labyrinthomyxa (species include marina),Labyrinthuloides (species include haliotidis, yorkensis), Diplophrys(species include archeri), Pyrrhosorus* (species include marinus),Sorodiplophrys* (species include stercorea), Chlamydomyxa* (speciesinclude labyrinthuloides, montana). (*=there is no current generalconsensus on the exact taxonomic placement of these genera).

Suitable microorganisms include those capable of producing lipidscomprising the labile compounds omega-3 and/or omega-6 polyunsaturatedfatty acids, and in particular microorganisms that are capable ofproducing DHA, DPA, EPA or ARA) will be described. More particularly,preferred microorganisms are algae, such as Thraustochytrids of theorder Thraustochytriales, including Thraustochytrium (including Ulkenia)and Schizochytrium and including Thraustochytriales which are disclosedin commonly assigned U.S. Pat. Nos. 5,340,594 and 5,340,742, both issuedto Barclay, all of which are incorporated herein by reference in theirentirety. More preferably, the microorganisms are selected from thegroup consisting of microorganisms having the identifyingcharacteristics of ATCC number 20888, ATCC number 20889, ATCC number20890, ATCC number 20891 and ATCC number 20892. Since there is somedisagreement among experts as to whether Ulkenia is a separate genusfrom the genus Thraustochytrium, for the purposes of this application,the genus Thraustochytrium will include Ulkenia. Also preferred arestrains of Mortierella schmuckeri (e.g., including ATCC 74371) andMortierella alpina. Also preferred are strains of Crypthecodiniumcohnii, including microorganisms having the identifying characteristicsof ATCC Nos. 30021, 30334-30348, 30541-30543, 30555-30557, 30571, 30572,30772-30775, 30812, 40750, 50050-50060, and 50297-50300. Oleaginousmicroorganisms are also preferred. As used herein, “oleaginousmicroorganisms” are defined as microorganisms capable of accumulatinggreater than 20% of the dry weight of their cells in the form of lipids.Genetically modified microorganisms that produce PUFAs are also suitablefor the present invention. These can include naturally PUFA-producingmicroorganisms that have been genetically modified as well asmicroorganisms that do not naturally produce PUFAs but that have beengenetically modified to do so.

Suitable organisms can be obtained from a number of available sources,including by collection from the natural environment. For example, theAmerican Type Culture Collection currently lists many publicly availablestrains of microorganisms identified above. As used herein, anyorganism, or any specific type of organism, includes wild strains,mutants, or recombinant types. Growth conditions in which to culture orgrow these organisms are known in the art, and appropriate growthconditions for at least some of these organisms are disclosed in, forexample, U.S. Pat. No. 5,130,242, U.S. Pat. No. 5,407,957, U.S. Pat. No.5,397,591, U.S. Pat. No. 5,492,938, and U.S. Pat. No. 5,711,983, all ofwhich are incorporated herein by reference in their entirety.

Another source of PUFAs, in the compositions and methods of the presentinvention includes a plant source, such as oilseed plants.PUFA-producing plants, in alternate embodiments, can include thosegenetically engineered to express genes that produce PUFAs and thosethat produce PUFAs naturally. Such genes can include genes encodingproteins involved in the classical fatty acid synthase pathways, orgenes encoding proteins involved in the PUFA polyketide synthase (PKS)pathway. The genes and proteins involved in the classical fatty acidsynthase pathways, and genetically modified organisms, such as plants,transformed with such genes, are described, for example, in Napier andSayanova, Proceedings of the Nutrition Society (2005), 64:387-393;Robert et al., Functional Plant Biology (2005) 32:473-479; or U.S.Patent Application Publication 2004/0172682. The PUFA PKS pathway, genesand proteins included in this pathway, and genetically modifiedmicroorganisms and plants transformed with such genes for the expressionand production of PUFAs are described in detail in: U.S. Pat. No.6,566,583; U.S. Patent Application Publication No. 20020194641, U.S.Patent Application Publication No. 20040235127A1, and U.S. PatentApplication Publication No. 20050100995A1, each of which is incorporatedherein by reference in its entirety.

Oilseed crops suitable for use in the present invention includesoybeans, corn, safflower, sunflower, canola, flax, peanut, mustard,rapeseed, chickpea, cotton, lentil, white clover, olive, palm oil,borage, evening primrose, linseed, and tobacco that have beengenetically modified to produce PUFA as described above.

Genetic transformation techniques for microorganisms and plants arewell-known in the art. Transformation techniques for microorganisms arewell known in the art and are discussed, for example, in Sambrook etal., 1989, Molecular Cloning: A Laboratory Manual, Cold Spring HarborLabs Press. A general technique for transformation of dinoflagellates,which can be adapted for use with Crypthecodinium cohnii, is describedin detail in Lohuis and Miller, The Plant Journal (1998) 13(3): 427-435.A general technique for genetic transformation of Thraustochytrids isdescribed in detail in U.S. Patent Application Publication No.20030166207, published Sep. 4, 2003. Methods for the genetic engineeringof plants are also well known in the art. For instance, numerous methodsfor plant transformation have been developed, including biological andphysical transformation protocols. See, for example, Miki et al.,“Procedures for Introducing Foreign DNA into Plants” in Methods in PlantMolecular Biology and Biotechnology, Glick, B. R. and Thompson, J. E.Eds. (CRC Press, Inc., Boca Raton, 1993) pp. 67-88. In addition, vectorsand in vitro culture methods for plant cell or tissue transformation andregeneration of plants are available. See, for example, Gruber et al.,“Vectors for Plant Transformation” in Methods in Plant Molecular Biologyand Biotechnology, Glick, B. R. and Thompson, J. E. Eds. (CRC Press,Inc., Boca Raton, 1993) pp. 89-119. See also, Horsch et al., Science227:1229 (1985); Kado, C. I., Crit. Rev. Plant. Sci. 10:1 (1991);Moloney et al., Plant Cell Reports 8:238 (1989); U.S. Pat. No.4,940,838; U.S. Pat. No. 5,464,763; Sanford et al., Part. Sci. Technol.5:27 (1987); Sanford, J. C., Trends Biotech. 6:299 (1988); Sanford, J.C., Physiol Plant 79:206 (1990); Klein et al., Biotechnology 10:268(1992); Zhang et al., Bio/Technology 9:996 (1991); Deshayes et al., EMBOJ, 4:2731 (1985); Christou et al., Proc Natl. Acad. Sci. USA 84:3962(1987); Hain et al., Mol. Gen. Genet. 199:161 (1985); Draper et al.,Plant Cell Physiol. 23:451 (1982); Donn et al., In Abstracts of VIIthInternational Congress on Plant Cell and Tissue Culture IAPTC, A2-38, p.53 (1990); D'Halluin et al., Plant Cell 4:1495-1505 (1992) and Spenceret al., Plant Mol. Biol. 24:51-61 (1994).

When oilseed plants are the source of PUFAs, the seeds can be harvestedand processed to remove any impurities, debris or indigestible portionsfrom the harvested seeds. Processing steps vary depending on the type ofoilseed and are known in the art. Processing steps can include threshing(such as, for example, when soybean seeds are separated from the pods),dehulling (removing the dry outer covering, or husk, of a fruit, seed,or nut), drying, cleaning, grinding, milling and flaking. After theseeds have been processed to remove any impurities, debris orindigestible materials, they can be added to an aqueous solution andthen mixed to produce a slurry. In some embodiments, milling, crushingor flaking is performed prior to mixing with water. A slurry produced inthis manner can be treated and processed the same way as described for amicrobial fermentation broth.

Another biomass source of nutrients, including PUFAs, in thecompositions and methods of the present invention includes an animalsource. Examples of animal sources include aquatic animals (e.g., fish,marine mammals, and crustaceans such as krill and other eupliausids) andanimal tissues (e.g., brain, liver, eyes, etc.) and animal products suchas eggs or milk. Techniques for recovery of PUFA-containing oils fromsuch sources are known in the art.

In some embodiments, the labile compound is a vitamin, such as, forexample, Vitamin A, Vitamin D, Vitamin E, Vitamin K, Vitamin B1, VitaminB2, Vitamin B3, Vitamin B6, Vitamin C, Folic Acid, Vitamin B-12, Biotin,Vitamin B5 or mixtures thereof.

In some embodiments, the labile compound is mineral, such as, forexample, calcium, iron, iodine, magnesium, zinc, selenium, copper,manganese, chromium, molybdenum, ionic forms of the foregoing,biologically acceptable salts of the foregoing, or mixtures thereof.

In some embodiments, the labile compound comprises an antioxidant,carotenoid or xanthophyll, such as, for example, lycopene, lutein,zeaxanthin, astaxanthin, alpha-lipoic acid, coenzymeQ, beta-carotene ormixtures thereof.

In some embodiments, the labile compound is an amino acid, such as, forexample, arginine, aspartic acid, carnitine, cysteine, glutamic acid,glutamine, glycine, histidine, isoleucine, leucine, lysine, methionine,phenylalanine, proline, serine, threonine, tryptophan, tyrosine, valine,SAM-e or mixtures thereof.

In some embodiments, the labile compound comprises a flavor agent, suchas a flavor (or essential) oil, oleoresin, other flavoring essence ormixtures thereof. The term flavor oil is generally recognized in the artto be a flavoring aromatic compound and/or oil or extract derived frombotanical sources, i.e. leaves, bark, or skin of fruits or vegetables,and which are usually insoluble in water. Examples of flavor oilsinclude peppermint oil, spearmint oil, cinnamon oil, oil of wintergreen,nut oil, licorice, vanilla, citrus oils, fruit essences and mixturesthereof. Citrus oils and fruit essences include apple, apricot, banana,blueberry, cherry, coconut, grape, grapefruit, lemon, lime, orange,pear, peaches, pineapple, plum, raspberry, strawberry, and mixturesthereof. Oleoresin extracts of spices includes, for example oleoresinextracts of tarragon, thyme, sage, rosemary, oregano, nutmeg, basil,bay, cardamom flavor, celery, cilantro, cinnamon, clove, coriander,cumin, fennel, garlic, ginger, mace, marjoram, capsicum, black pepper,white pepper, annatto, paprika, turmeric, cajun, and mixtures thereof.

Without intending to be bound by any theory, the first encapsulant isbelieved to protect the composition comprising the labile compound toreduce the likelihood of or degree to which the labile compoundundergoes a chemical, physical, or biological change or breakdown. Thefirst encapsulant can form a continuous coating on the compositioncomprising the labile compound (100% encapsulation) or alternatively,form a non-continuous coating (e.g., at a level that providessubstantial coverage of the labile compound, for example, coverage at80%, 90%, 95%, or 99%). In other embodiments, the first encapsulant canbe a matrix in which the labile compound is entrapped.

In various embodiments, the composition comprising the labile compoundwith a first encapsulant can be any of an encapsulated compositioncomprising a labile compound, a whole cell biomass, a biomasshydrolysate, or an oilseed.

Encapsulation of compositions comprising labile compounds, includingPUFAs, with a first encapsulant can be by any method known in the art.For example, the composition comprising a labile compound can bespray-dried. Other methods for encapsulation are known, such as fluidbed drying, drum (film) drying, coacervation, interfacialpolymerization, fluid bed processing, pan coating, spray gelation,ribbon blending, spinning disk, centrifugal coextrusion, inclusioncomplexation, emulsion stabilization, spray coating, extrusion, liposomenanoencapsulation, supercritical fluid microencapsulation, suspensionpolymerization, cold dehydration processes, spray cooling/chilling(prilling), evaporative dispersion processes, and methods that takeadvantage of differential solubility of coatings at varyingtemperatures.

Some exemplary encapsulation techniques are summarized below. It shouldbe recognized that reference to the various techniques summarized belowincludes the description herein and variations of those descriptionsknown to those in the art.

In spray drying, the core material to be encapsulated is dispersed ordissolved in a solution. Typically, the solution is aqueous and thesolution includes a polymer. The solution or dispersion is pumpedthrough a micronizing nozzle driven by a flow of compressed gas, and theresulting aerosol is suspended in a heated cyclone of air, allowing thesolvent to evaporate from the microdroplets. The solidifiedmicroparticles pass into a second chamber and are trapped in acollection flask.

Interfacial polycondensation is used to encapsulate a core material inthe following manner. One monomer and the core material are dissolved ina solvent. A second monomer is dissolved in a second solvent (typicallyaqueous) which is immiscible with the first. An emulsion is formed bysuspending the first solution in the second solution by stirring. Oncethe emulsion is stabilized, an initiator is added to the aqueous phasecausing interfacial polymerization at the interface of each droplet ofemulsion.

In hot melt encapsulation the core material is added to molten polymer.This mixture is suspended as molten droplets in a nonsolvent for thepolymer (often oil-based) which has been heated to approximately 10° C.above the melting point of the polymer. The emulsion is maintainedthrough vigorous stirring while the nonsolvent bath is quickly cooledbelow the glass transition of the polymer, causing the molten dropletsto solidify and entrap the core material.

In solvent evaporation encapsulation, a polymer is typically dissolvedin a water immiscible organic solvent and the material to beencapsulated is added to the polymer solution as a suspension orsolution in organic solvent. An emulsion is formed by adding thissuspension or solution to a vessel of vigorously stirred water (oftencontaining a surface active agent to stabilize the emulsion). Theorganic solvent is evaporated while continuing to stir. Evaporationresults in precipitation of the polymer, forming solid microcapsulescontaining core material.

The solvent evaporation process is designed to entrap a liquid corematerial in a polymer, copolymer, or copolymer microcapsules. Thepolymer or copolymer is dissolved in a miscible mixture of solvent andnonsolvent, at a nonsolvent concentration which is immediately below theconcentration which would produce phase separation (i.e., cloud point).The liquid core material is added to the solution while agitating toform an emulsion and disperse the material as droplets. Solvent andnonsolvent are vaporized, with the solvent being vaporized at a fasterrate, causing the polymer or copolymer to phase separate and migratetowards the surface of the core material droplets. This phase separatedsolution is then transferred into an agitated volume of nonsolvent,causing any remaining dissolved polymer or copolymer to precipitate andextracting any residual solvent from the formed membrane. The result isa microcapsule composed of polymer or copolymer shell with a core ofliquid material.

In solvent removal encapsulation, a polymer is typically dissolved in anoil miscible organic solvent and the material to be encapsulated isadded to the polymer solution as a suspension or solution in organicsolvent. An emulsion is formed by adding this suspension or solution toa vessel of vigorously stirring oil, in which the oil is a nonsolventfor the polymer and the polymer/solvent solution is immiscible in theoil. The organic solvent is removed by diffusion into the oil phasewhile continuing to stir. Solvent removal results in precipitation ofthe polymer, forming solid microcapsules containing core material.

In phase separation encapsulation, the material to be encapsulated isdispersed in a polymer solution by stirring. While continuing touniformly suspend the material through stirring, a nonsolvent for thepolymer is slowly added to the solution to decrease the polymer'ssolubility. Depending on the solubility of the polymer in the solventand nonsolvent, the polymer either precipitates or phase separates intoa polymer rich and a polymer poor phase. Under proper conditions, thepolymer in the polymer rich phase will migrate to the interface with thecontinuous phase, encapsulating the core material in a droplet with anouter polymer shell.

Spontaneous emulsification involves solidifying emulsified liquidpolymer droplets by changing temperature, evaporating solvent, or addingchemical cross-linking agents. Physical and chemical properties of theencapsulant and the material to be encapsulated dictates suitablemethods of encapsulation. Factors such as hydrophobicity, molecularweight, chemical stability, and thermal stability affect encapsulation.

Coacervation is a process involving separation of colloidal solutionsinto two or more immiscible liquid layers (Dowben, R. GeneralPhysiology, Harper & Row, New York, 1969, pp. 142-143). Through theprocess of coacervation compositions comprised of two or more phases andknown as coacervates may be produced. The ingredients that comprise thetwo phase coacervate system are present in both phases; however, thecolloid rich phase has a greater concentration of the components thanthe colloid poor phase.

Low temperature microsphere formation has been described, see, e.g.,U.S. Pat. No. 5,019,400. The method is a process for preparingmicrospheres which involves the use of very cold temperatures to freezepolymer-biologically active agent mixtures into polymeric microspheres.The polymer is generally dissolved in a solvent together with an activeagent that can be either dissolved in the solvent or dispersed in thesolvent in the form of microparticles. The polymer/active agent mixtureis atomized into a vessel containing a liquid non-solvent, alone orfrozen and overlayed with a liquefied gas, at a temperature below thefreezing point of the polymer/active agent solution. The cold liquefiedgas or liquid immediately freezes the polymer droplets. As the dropletsand non-solvent for the polymer is warmed, the solvent in the dropletsthaws and is extracted into the non-solvent, resulting in hardenedmicrospheres.

Phase separation encapsulation generally proceeds more rapidly than theprocedures described in the preceding paragraphs. A polymer is dissolvedin the solvent. An agent to be encapsulated then is dissolved ordispersed in that solvent. The mixture then is combined with an excessof nonsolvent and is emulsified and stabilized, whereby the polymersolvent no longer is the continuous phase. Aggressive emulsificationconditions are applied in order to produce microdroplets of the polymersolvent. After emulsification, the stable emulsion is introduced into alarge volume of nonsolvent to extract the polymer solvent and formmicroparticles. The size of the microparticles is determined by the sizeof the microdroplets of polymer solvent.

Another method for encapsulating is by phase inversion nanoencapsulation(PIN). In PIN, a polymer is dissolved in an effective amount of asolvent. The agent to be encapsulated is also dissolved or dispersed inthe effective amount of the solvent. The polymer, the agent and thesolvent together form a mixture having a continuous phase, wherein thesolvent is the continuous phase. The mixture is introduced into aneffective amount of a nonsolvent to cause the spontaneous formation ofthe microencapsulated product, wherein the solvent and the nonsolventare miscible.

In preparing a first encapsulant of a composition comprising a labilecompound the conditions can be controlled by one skilled in the art toyield encapsulated material with the desired attributes. For example,the average particle size, hydrophobicity, biocompatibility, ratio ofcore material to encapsulant, thermal stability, and the like can bevaried by one skilled in the art.

In the instance where the composition comprising the labile compoundwith a first encapsulant comprises a whole cell biomass, it will berecognized that the cell, e.g., a microbial cell, can include a labilecompound such as a PUFA, a vitamin or other beneficial compound. Wholecells include those described above as sources for PUFAs. The cellularstructure (e.g., a cell wall or cell membrane), at least in part,constitutes the first encapsulant and it provides protection to thelabile compound by virtue of isolating it from the surroundingenvironment. As used herein, biomass can refer to multiple whole cellsthat, in the aggregate, constitute a biomass. A microbial biomass canrefer to a biomass that has not been separated from the culture media inwhich the biomass organism was cultured. An example of a culture mediais a fermentation broth. In a further embodiment, the biomass isseparated from its culture media by a solid/liquid separation prior totreatment by methods of the present invention. Typical solid/liquidseparation techniques include centrifugation, filtration, and membranefilter pressing (plate and frame filter press with squeezing membranes).This (harvested) biomass usually has a dry matter content varyingbetween 5% and 60%. If the water content is too high, the biomass can bedewatered by any method known in the art, such as, for example, spraydrying, fluidized bed drying, lyophilization, freeze drying, traydrying, vacuum tray drying, drum drying, solvent drying, excipientdrying, vacuum mixer/reactor drying, drying using spray bed drying,fluidized spray drying, conveyor drying, ultrafiltration, evaporation,osmotic dehydration, freezing, extrusion, absorbent addition or othersimilar methods, or combinations thereof. The drying techniquesreferenced herein are well known in the art. For example, excipientdrying refers to the process of atomizing liquids onto a bed of materialsuch as starch and solvent drying refers to a process where a solvent,miscible with water, is used in excess to replace the water. The biomasscan optionally be washed in order to reduce extracellular components.The fermentation broth can be dried and then reconstituted to a moisturecontent of any desired level before treatment by any of the methods ofthe present invention. Alternatively, hydrolyzing enzymes can be appliedto dried biomass to form a biomass hydrolysate, described elsewhereherein.

In a further embodiment in which the composition comprising the labilecompound with a first encapsulant comprises a whole cell, the whole cellis a probiotic organism. As is well understood, probiotics aremicroorganisms that are intended to confer a beneficial health effectwhen consumed by favorably altering the intestinal microflora balance,inhibiting the growth of harmful bacteria, producing beneficialcompositions, promoting good digestion, boosting immune function, and/orincreasing resistance to infection. For example, Lactobacillusacidophilus is considered to be beneficial because it produces vitaminK, lactase, and anti-microbial substances such as acidolin,acidolphilin, lactocidin, and bacteriocin. Probiotics include, forexample, lactic acid bacteria, and bifidobacteria. Lactic acid bacteriainclude, for example, Lactococcus lactis, Lactobacillus acidolphilus,Lactobacillus crispatus, Lactobacillus amylovorous, Lactobacillusgallinarum, Lactobacillus gasseri, Lactobacillus johnsonii,Lactobacillus rhamnosus, Lactobacillus brevis, Lactobacillus fermentum,Lactobacillus plantarum, Lactobacillus helveticus, Lactobacillus casei,Lactobacillus delbruckii, Lactobacillus bulgaricus, Lactobacillusplantarum, and Lactobacillus GG. Bifidobacteria include, for example,Bifidobacterium bifidum, Bifidobacterium breve, Bifidobacteriuminfantis, and Bifidobacterium longum. Additional probiotic bacteriainclude, for instance, Streptococcus thermophilus and Leuconostocmesenteroides. Without intending to be bound by theory, the beneficialeffects of these microorganisms can be preserved if encapsulated by asecond encapsulant. In one embodiment, the probiotic microorganism isencapsulated under conditions in which the microorganism retains itsbeneficial probiotic properties. For example, encapsulation with asecond encapsulant can be performed at a temperature lower than thetemperature required for inactivation of the microorganism, generally inthe range of 90-100° C.

In a further embodiment, the composition comprising the labile compoundwith a first encapsulant comprises an emulsified biomass hydrolysate.Such compositions and methods for making the same are described indetail in U.S. Provisional Patent Application Ser. No. 60/680,740, filedon May 12, 2005; U.S. Provisional Patent Application Ser. No.60/781,430, filed on Mar. 10, 2006; and U.S. patent application Ser. No.11/433,752, filed on May 12, 2006, all of which are incorporated hereinby reference. Briefly, an emulsified biomass hydrolysate is obtained byhydrolyzing a nutrient-containing biomass to produce a hydrolyzedbiomass, and emulsifying the hydrolyzed biomass to fonn a stableproduct. The stable product is typically an emulsion or a drycomposition resulting from subsequent drying of the emulsion.

In a further embodiment, the composition comprising the labile compoundwith a first encapsulant comprises an oilseed. Such oilseeds can beselected from those generally described above as sources for PUFAs andcan include oilseeds from plants that have been genetically modified andplants that have not been genetically modified.

As noted above, products of the present invention include a secondencapsulant of the first encapsulant. Without intending to be bound bytheory, the second encapsulant of the first encapsulant is believed tofurther protect the composition comprising the labile compound to reducethe likelihood of or degree to which the labile compound undergoes achemical, physical, or biological change or breakdown. The secondencapsulant can form a continuous coating on the first encapsulant (100%encapsulation) or alternatively, fonn a non-continuous coating (e.g., ata level that provides substantial coverage of the first encapsulant, forexample, coverage at 80%, 90%, 95%, or 99%). In other embodiments, thesecond encapsulant can be a matrix in which the first encapsulant isentrapped.

The second encapsulant can be applied by any method known in the art,such as spray drying, fluid bed drying, drum (film) drying,coacervation, interfacial polymerization, fluid bed processing, pancoating, spray gelation, ribbon blending, spinning disk, centrifugalcoextrusion, inclusion complexation, emulsion stabilization, spraycoating, extrusion, liposome nanoencapsulation, supercritical fluidmicroencapsulation, suspension polymerization, cold dehydrationprocesses, spray cooling/chilling (prilling), evaporative dispersionprocesses, and methods that take advantage of differential solubility ofcoatings at varying temperatures. While a second encapsulant canencapsulate a single discrete particle (i.e., a particle that is a firstencapsulant of a composition comprising a labile compound), a secondencapsulant can alternatively encapsulate a plurality of discreteparticles within a single second encapsulant.

In preferred embodiments, the second encapsulant of the firstencapsulant is a prill coating. Prilling is a process of encapsulatingcompounds in a high temperature melt matrix wherein the prillingmaterial goes from solid to liquid above room temperature. As usedherein, a prill coating is a wax, oil, fat, or resin, typically having amelting point of about 25-150° C. The prill coating can envelop thefirst encapsulant completely (100% encapsulation), or the prill coatingcan envelop the first encapsulant at some level less than 100%, but at alevel which provides substantial coverage of the first encapsulant, forexample, at about 50%, about 60%, about 70%, about 80%, about 90%, about95%, or about 99%. In some embodiments, the prill coating is edible.More particularly, the prill coating can comprise, for example, a fattyacid monoglyceride; a fatty acid diglyceride; a fatty acid triglyceride;a free fatty acid (such as stearic acid, palmitic acid, and oleic acid);tallow (such as beef tallow, mutton tallow, and lamb tallow); lard (porkfat); beeswax; lanolin; shell wax; insect wax including Chinese insectwax; vegetable wax, carnauba wax; candelilla wax; bayberry wax; sugarcane wax; mineral wax; paraffin microcrystalline petroleum wax;ozocerite wax; ceresin wax; montan synthetic wax, low molecular weightpolyolefin; polyol ether-esters, sorbitol; Fischer-Tropsch processsynthetic wax; rosin; balsam; shellac; stearylamide;ethylenebisstearylamide; hydrogenated castor oil; esters ofpentaerythritol; mono and tetra esters of stearic acid; vegetable oil(such as cottonseed oil, sunflower oil, safflower oil, soybean oil, cornoil, olive oil, canola oil, linseed oil, flaxseed oil); hydrogenatedvegetable oil; and mixtures and derivatives of the foregoing. In someembodiments, the prill coating is hydrogenated cottonseed oil,hydrogenated sunflower oil, hydrogenated safflower oil, hydrogenatedsoybean oil, hydrogenated corn oil, hydrogenated olive oil, hydrogenatedcanola oil, hydrogenated linseed oil, or hydrogenated flaxseed oil.

In some embodiments, the prill coating further comprises an additionalcomponent. The additional component can be, for example, a fat-solubleor fat dispersible antioxidant, oxygen scavenger, colorant or flavoragent. Such an antioxidant can be, for example, vitamin E, tocopherol,butylhydroxytoluene (BHT), butylhydroxyanisole (BHA),tert-butylhydroquinone (TBHQ), propyl gallate (PG), vitamin C, ascorbylpalmitate, phospholipids, a Maillard reaction product, naturalantioxidants (such as spice extracts, e.g., rosemary or oreganoextracts, and seed extracts, e.g., grapeseed extracts or pomegranateextract), and combinations thereof. The Maillard reaction product can beadded as an antioxidant in addition to Maillard reaction productsdescribed elsewhere. Such an oxygen scavenger can be, for example,ascorbic acid, isoascorbic acid, erythorbic acid, or mixtures of saltsthereof. The colorant component is selected from the group consisting ofwater soluble natural or artificial dyes that include FD&C dyes (food,drug and cosmetic use dyes) of blue, green, orange, red, yellow andviolet; iron oxide dyes; ultramarine pigments of blue, pink, red andviolet; and equivalents thereof. The dyes discussed above are wellknown, and are commercially available materials. Examples of flavoragents include flavor oils such as peppermint oil, spearmint oil,cinnamon oil, oil of wintergreen, nut oil, licorice, vanilla, citrusoils, fruit essences and mixtures thereof. Citrus oils and fruitessences include apple, apricot, banana, blueberry, cherry, coconut,grape, grapefruit, lemon, lime, orange, pear, peaches, pineapple, plum,raspberry, strawberry, and mixtures thereof. Other examples of flavoragents include oleoresin extracts of spices includes, for exampleoleoresin extracts of tarragon, thyme, sage, rosemary, oregano, nutmeg,basil, bay, cardamom flavor, celery, cilantro, cinnamon, clove,coriander, cumin, fennel, garlic, ginger, mace, marjoram, capsicum,black pepper, white pepper, annatto, paprika, turmeric, cajun, andmixtures thereof.

In some embodiments, the prill coating is applied by a prilling methodwith the resultant product being a prill or bead. Prilling is also knownin the art as spray cooling, spray chilling, and/or matrixencapsulation. Prilling is similar to spray drying in that a corematerial, in the present case, a first encapsulant of a compositioncomprising a labile compound, is dispersed in a liquefied coating orwall material and atomized. Unlike spray drying, there is no waterpresent to be evaporated. The core material and the second encapsulantcan be atomized into cooled or chilled air, which causes the wall tosolidify around the core. In spray chilling, the prill coating typicallyhas a melting point between about 32° C. and about 42° C. In spraycooling, the prill coating typically has a melting point of betweenabout 45° C. and about 122° C. In some embodiments, the prill coating isapplied by a modified prilling method. A modified prilling method, forexample, can be a spinning disk process or centrifugal coextrusionprocess. In some embodiments, the product having a prill coating is in aform that results in a free-flowing powder.

In some embodiments, the prill coating is applied so as to form aproduct into configurations other than powders, such as chips or flakes.In all such embodiments, the equipment converts the liquid prill coatingmaterial into a solid by cooling it while it is applied to a firstencapsulated product. For example, the prill coating and firstencapsulant of a composition comprising a labile compound are cooled asthe mixture passes through rollers and is formed into a flat sheet,which can then be processed into chips or flakes. Alternatively, themixture can be extruded through dies to form shapes or through blades tobe cut into ribbons.

In a further embodiment, the second encapsulant of the first encapsulantis a fluid bed coating. Application of a fluid bed coating is wellsuited to uniformly coat or encapsulate individual particulatematerials. The apparatus for applying a fluid bed coating is typicallycharacterized by the location of a spray nozzle at the bottom of afluidized bed of solid particles, and the particles are suspended in afluidizing air stream that is designed to induce cyclic flow of theparticles past the spray nozzle. The nozzle sprays an atomized flow ofcoating solution, suspension, or other coating material. The atomizedcoating material collides with the particles as they are carried awayfrom the nozzle. The temperature of the fluidizing air is set toappropriately solidify the coating material shortly after colliding withthe particles. Suitable coating materials include the materialsidentified above as materials for prill coatings. For example, hot-meltcoatings are a solid fat (at room temperature) that has been melted andsprayed on to a particle (i.e., a first encapsulant) where itsolidifies. A benefit of using hot-melt coatings is that they have nosolvent to evaporate and are insoluble in water, they are also low costand easily obtainable. Typical coating volume for hot-melt applicationto a first encapsulant is 50% (one half hot-melt coating and one halffirst encapsulant and core material).

Additional encapsulants, for example, a third encapsulant, a fourthencapsulant, a fifth encapsulant, and so on, are also contemplated inthe present invention. Additional encapsulants can be applied by methodsdescribed herein, and can provide additional desirable properties to theproducts. For example, the additional encapsulants can further enhancethe shelf life of the products, or modify the release properties of theproduct to provide for controlled release or delayed release of thelabile compound.

In some embodiments, the product further comprises a Maillard reactionproduct (MRP). The Maillard reaction occurs when reducing sugars andamino acids react. A reducing sugar is a sugar with a ketone or analdehyde functional group, which allows the sugar to act as a reducingagent in the Maillard reaction. This reaction occurs in most foods onheating. Maillard reaction chemistry can affect desirable flavors andcolor of a wide range of foods and beverages. While not being bound bytheory, it is believed that formation of MRPs in the products of theinvention produces aromas and flavors that are desirable for inclusionin food products or other products that are consumed. MRPs can alsopossess antioxidant activity, and without being bound by theory, it isbelieved that this property of the MRPs imparts increased stability andshelf life to the products of the present invention. The Maillardreactions are well-known and from the detailed specification herein,temperature and time required to carry the reaction to the desiredextent can be determined.

MRPs can be included in the products of the present invention in anumber of ways. In some embodiments, the MRP is a product of a reducingsugar and an amino acid source that is a protein. Proteins that can beused to produce an MRP include casein, whey solids, whey proteinisolate, soy protein, skim milk powder, hydrolyzed casein, hydrolyzedwhey protein, hydrolyzed soy protein, non-fat milk solids, gelatin,zein, albumin, and the like. Alternatively, amino acids can be provideddirectly or by in situ formation, such as by acid, alkaline or enzymatichydrolysis. In various embodiments, the reducing sugar can includesugars, such as fructose, glucose, glyceraldehyde, lactose, arabinose,and maltose. As used herein, the term reducing sugar also includescomplex sources of reducing sugars. For example, suitable complexsources include corn syrup solids and modified starches such aschemically modified starches and hydrolysed starches or dextrins, suchas maltodextrin. Hydrolysed starches (dextrins) are used in someembodiments. In some embodiments, the reducing sugar is formed in situfrom, for example, a compound that is not itself a reducing sugar, butcomprises reducing sugars. For example, starch is not a reducing sugar,but is a polymer of glucose, which is a reducing sugar. Hydrolysis ofstarch, by chemical or enzymatic means, yields glucose. This hydrolysiscan take place in situ, to provide the reducing sugar glucose.

The reducing sugars and protein used to form MRPs in various embodimentsof the present invention can naturally occur in the first encapsulant ofthe composition or the second encapsulant. For example, in the instanceof the first encapsulant being a microbial biomass hydrolysate emulsion,the reducing sugars and proteins can be present without being added.Alternatively, various embodiments of the invention contemplate theaddition of some or all of the reducing sugar and protein.

In one embodiment, an MRP is formed by contacting the first encapsulantwith the second encapsulant. Thus, the invention provides in a furtherembodiment, a product comprising a composition comprising a labilecompound, a first encapsulant of the composition, and a secondencapsulant of the first encapsulant, wherein the product furthercomprises an MRP formed by contacting the first encapsulant with thesecond encapsulant. In this embodiment, at the time the firstencapsulant and second encapsulants are brought into contact, they aredone so in the presence of reducing sugars and protein under suitabletemperature and time conditions to form MRPs. For example, when thesecond encapsulant is a prill coating, contacting the first encapsulantwith the liquefied prill coating at elevated temperature in the presenceof reducing sugars and proteins can promote the formation of MRPs. Ingeneral, the temperature of such a reaction ranges from about 20° C. toabout 150° C. with from about 80° C. to about 110° C. being preferred.The time of the reaction ranges from about 1 minute to about severalhours, depending on the temperature. At the preferred higher temperaturerange, the time of reaction is preferably about 1 minute to about 20minutes. Reference to “time of reaction” in this paragraph refers to thetime that the first encapsulant is in contact with the liquefied prillcoating before cooling to solidify the coating.

In another embodiment, the Maillard reaction product is formed in anon-aqueous environment. Accordingly, in one embodiment, the inventionprovides a product comprising a composition comprising a labilecompound, a first encapsulant of the composition, and a secondencapsulant of the first encapsulant, wherein the product furthercomprises a Maillard reaction product formed in a non-aqueousenvironment. For example, when the second encapsulant is a prillcoating, contacting the first encapsulant with the liquefied prillcoating at elevated temperature in the presence of reducing sugars andproteins can promote the formation of MRPs in the environment of theliquefied prill coating, i.e., a non-aqueous environment. In thisembodiment, the reaction is analogous to browning in oil. Water isproduced as a byproduct of the Maillard reaction, and therefore thepresence of water is inhibitory for the formation of MRPs. Thus, itshould be recognized that reference to a non-aqueous environment,encompasses an environment comprising small amounts of water, such asthat produced by the Maillard reaction. By carrying out the Maillardreaction in a non-aqueous environment, it is believed that the reactionoccurs more readily than it would in the presence of water and thatreaction times are therefore reduced significantly. Additionally,undesirable side products that can form upon heating the reaction areminimized with shorter reaction times. For example, in the case where aPUFA is the labile compound, oxidation products that form upon heatingare reduced. Thus the resulting product contains a high-quality PUFAwhich contains little or no oxidation products.

In some embodiments, the first encapsulated product comprises the aminoacid source and the reducing sugar source. In some embodiments, thefirst encapsulated product comprises the amino acid source and thesecond encapsulant comprises the reducing sugar source. In otherembodiments, the first encapsulated product comprises the reducing sugarsource and the second encapsulant comprises the amino acid source. Instill other embodiments, the second encapsulant comprises the reducingsugar and the amino acid source. In other embodiments, the amino acidsource and/or the reducing sugar source can be present in both the firstencapsulated product and the second encapsulant.

In another embodiment, the second encapsulant comprises an MRP.Accordingly, in one embodiment, the invention provides a productcomprising a composition comprising a labile compound, a firstencapsulant of the composition, a second encapsulant of the firstencapsulant, wherein the second encapsulant further comprises a Maillardreaction product. In this embodiment, for example, the MRP can beproduced separately and introduced into the second encapsulant prior toencapsulation of the first encapsulant. Alternatively, in embodiments inwhich one or both of the reducing sugar and amino acid source are in thesecond encapsulant, MRPs will be formed throughout the secondencapsulant. As the second encapsulant is cooled and formed into acoating, as in a prilling process, the MRPs will be dispersed throughoutthe second encapsulant. In such embodiments, MRPs will occur, not justat the interface between the first and second encapsulants, but in theouter portions of the second encapsulant away from the firstencapsulant. For example, the MRPs will occur in the outer 75%, 50% or25% of the second encapsulant.

The products of the present invention can be is characterized in generalby parameters such as particle size and distribution, particle geometry,active contents and distribution, release mechanism, and storagestability. In some embodiments in which the product is in a powder fonn,the product has a particle size of between about 10 μm and about 3000μm, and in another embodiment between about 40 μm and 300 μm. Generally,the products are insoluble in cold to warm water, and in someembodiments, have a water solubility of less than about 0.1 mg/ml. Thesolubility of the product in a given environment will depend on themelting point of the second encapsulant. One skilled in the art canselect an appropriate second encapsulant for the anticipated use andenvironment for the product.

The products of the invention are generally physically stable. In someembodiments, the product is physically stable for at least about 30days, at least about 60 days, at least about 90 days, at least about 120days, at least about one year, at least about three years, or at leastabout five years. Physical stability refers to the ability of a productto maintain its physical appearance over time. For example, thestructure of a product, with the first encapsulant of the compositionand the second encapsulant of the first encapsulant, is substantiallymaintained without, for example, the composition migrating through thefirst encapsulant to the second encapsulant.

In various embodiments, the products the invention are oxidativelystable. As used herein, oxidative stability refers to the lack ofsignificant oxidation in the labile compound over a period of time.Oxidative stability of fats and oils can be determined by one skilled inthe art. For example, peroxide values indicate the amount of peroxidespresent in the fat and are generally expressed in milli-equivalentoxygen per kg fat or oil. Additionally, anisidine values measurecarbonyl (aldehydes and ketones) components which are formed duringdeterioration of oils. Anisidine values can be determined as describedin IUPAC, Standard Methods for the Analysis of Oils, Fats andDerivatives, 6th Ed. (1979), Pergamon Press, Oxford, Method 2,504, page143. The products of the invention, in some embodiments, have a peroxidevalue of less than about 2, or less than about 1. In other embodiments,products of the invention have an anisidine value of less than about 1.In some embodiments, the product is oxidatively stable for at leastabout 30 days, at least about 60 days, at least about 90 days, at leastabout 120 days, at least about one year, at least about three years, orat least about five years.

In other embodiments of the invention, the products have desirablearomas or flavors. In some embodiments, a desirable aroma or flavor isdue to the presence of Maillard reaction products. In other embodiments,a desirable aroma or flavor, or lack of an undesirable aroma or flavor,is imparted to the product by the physical and oxidative stability ofthe product. The presence of desirable aromas and flavors can beevaluated by one skilled in the art. For example, the room-odorcharacteristics of cooking oils can be reproducibly characterized bytrained test panels in room-odor tests (Mounts, J. Am. Oil Chem. Soc.56:659-663, 1979). A standardized technique for the sensory evaluationof edible vegetable oils is presented in AOCS' Recommended Practice Cg2-83 for the Flavor Evaluation of Vegetable Oils (Methods and StandardPractices of the AOCS, 4th Edition (1989)). The technique encompassesstandard sample preparation and presentation, as well as referencestandards and method for scoring oils. Panelists can be asked to rankthe products on a Hedonic scale. Such a scale can be a scale of 1-10used for the overall odor and flavor in which 10 is assigned to“complete blandness”, and 1 to “strong obnoxiousness”. The higher scorewill indicate better product in terms of aroma and flavor. In someembodiments, products of the present invention will have a score of atleast about 5, at least about 6, at least about 7, at least about 8, atleast about 9 or about 10 in such a test. Such evaluations can beconducted at various time frames, such as upon production of theproduct, at least about 60 days after production, at least about 90 daysafter production, at least about 120 days after production, at leastabout one year after production, at least about three years afterproduction, or at least about five years after production.

The amount of labile compound in the products of the invention will varydepending on the type of compound, the encapsulation materials used, andthe methods used for forming the product. In some embodiments, theproduct comprises labile compound in an amount of at least about 1 to 20weight percent, in 1% increments and up to about 40 to 80 weightpercent, in 1% increments, for example, between about 1 weight percentand about 80 weight percent, between about 5 weight percent and about 70weight percent, between about 10 weight percent and about 60 weightpercent, or between about 15 weight percent and about 50 weight percent.

The present invention also provides methods for preparing the productsdescribed herein. Some of these methods have been described above.

In one particular embodiment, the invention provides a method forpreparing a product comprising encapsulating a first encapsulatedproduct in the presence of an amino acid source and a reducing sugar toform a second encapsulated product. In the process of encapsulating afirst encapsulated product, Maillard reaction products are formed. Inthis embodiment, the first encapsulated product comprises an encapsulantof a labile compound.

In some embodiments, this method further includes handling the labilecompound under conditions that reduce oxidative degradation prior toencapsulation. Such handling can include, for example, maintaining theproduct in an inert atmosphere, the addition of antioxidants to thelabile compound, and so forth. In some embodiments, this method furthercomprises processing the second encapsulated product into a particulateform. In some embodiments, the particulate form can be selected from thegroup consisting of a bead, a chip, and a flake.

In one embodiment, the first encapsulated product is formed by a methodcomprising emulsifying an aqueous dispersion of a polyunsaturated fattyacid, protein and reducing sugar to form an emulsion. This methodfurther includes drying the emulsion to form the first encapsulatedproduct.

In some embodiments, encapsulating the first encapsulated productcomprises contacting the first encapsulated product with a prillingmaterial, spraying the mixture of the first encapsulated product withthe prilling material into droplets, and cooling the droplets below themelting point of the prilling material to form the second encapsulatedproduct. In some embodiments, the prilling material has a melting pointin the range of about 32° C. to about 122° C. In other embodiments, thestep of contacting the first encapsulated product with the prillingmaterial is conducted at a temperature above about 85° C. In still otherembodiments, the step of contacting the first encapsulated product withthe prilling material is conducted for between about 1 minute and about15 minutes. In some embodiments, the prilling material is hydrogenatedvegetable oil, and the step of contacting the first encapsulated productwith the prilling material is conducted for between about 1 minute andabout 15 minutes, between 80° C. and 100° C.

In some embodiments, the first encapsulated product comprises about 25wt % to about 80 wt % labile compound; about 5 wt % to about 25 wt % ofan amino acid source; and about 15 wt % to about 70 wt % of a reducingsugar.

The products of the present invention can be incorporated intonutritional products (including food products, food supplements, feedproducts, feed supplements, and nutraceutical products), cosmeticproducts, pharmaceutical products, and industrial products. Products canbe in the form of chewable tablets, quick dissolve tablets, effervescenttablets, reconstitutable powders, elixirs, liquids, solutions,suspensions, emulsions, tablets, multi-layer tablets, bi-layer tablets,capsules, soft gelatin capsules, hard gelatin capsules, caplets,lozenges, chewable lozenges, beads, powders, granules, particles,dispersible granules, dietary supplements, genetically engineereddesigner foods, herbal products, and processed foods.

A nutritional product may be used directly as a food product, foodsupplement, feed product, feed supplement or as an ingredient in any ofthe foregoing. Food products can be liquid food products or solid foodproducts. Liquid food products include, for example, infant formula,liquid meals, liquid eggs, multivitamin syrups, meal replacers,medicinal foods, soups and syrups, and beverages. As used herein abeverage is any one of various liquids for drinking. Beverages include,for example, energy drinks, fruit juices, milk, and milk products. Solidfood products include, for example, baby food, yogurt, cheese, cereal,powdered mixes, baked goods, including, for example, such items ascakes, cheesecakes, pies, cupcakes, cookies, bars, breads, rolls,biscuits, muffins, pastries, scones, and croutons, food bars includingenergy bars, and processed meats. Also included are doughs, batters, icecreams; frozen desserts; frozen yogurts; waffle mixes; salad dressings;and replacement egg mixes, baked goods such as cookies, crackers, sweetgoods, snack cakes, pies, granola/snack bars, and toaster pastries;salted snacks such as potato chips, corn chips, tortilla chips, extrudedsnacks, popcorn, pretzels, potato crisps, and nuts; specialty snackssuch as dips, dried fruit snacks, meat snacks, pork rinds, health foodbars and rice/corn cakes; and confectionary snacks such as candy. Insome embodiments, particularly including some solid food products, theproduct can be processed into a particulate form. For example, theparticulate form can be selected from the group consisting of a bead, achip, and a flake.

Feed or feed supplements can be prepared for any companion animal or petor for any animal whose meat or products are consumed by humans. Theterm “animal” means any organism belonging to the kingdom Animalia andincludes, without limitation, any animal from which poultry meat,seafood, beef, pork or lamb is derived. Seafood is derived from, withoutlimitation, fish, shrimp and shellfish. Animal product includes anyproduct other than meat derived from such animals, including, withoutlimitation, eggs, milk or other products. When fed to such animals,nutrients such as LC PUFAs can be incorporated into the flesh, milk,eggs or other products of such animals to increase their content ofthese nutrients.

A cosmetic product is a product that is applied to the skin and canfunction either to improve the appearance of the skin or to provide somedermatological benefit to the skin.

An industrial product is a product such as a raw material formanufacturing paints, wood products, textiles, adhesives, sealants,lubricants, leather, rope, paper pulp, plastics, fuels, oil, rubberworking fluids, or metal working fluids.

Additional objects, advantages, and novel features of this inventionwill become apparent to those skilled in the art upon examination of thefollowing examples thereof, which are not intended to be limiting.

EXAMPLES Example 1

This example illustrates the production of a product of the presentinvention in which the composition comprising a labile compound is analgal oil and the first encapsulant is formed by spray drying. Thesecond encapsulant is a prill coating of hydrogenated canola wax.

Spray dried particles of algal oil in a sugar-protein matrix, preparedin accordance with the process generally described in EP 1 616 486,entitled Powdered Compositions Containing an Edible Oil and Their Use inFood Products, which is incorporated herein by reference, with a meansize of 78 μm were prilled in hydrogenated canola wax (Stable Flake—CN,Cargill). This material was prilled at a concentration of 33% (one-thirdby weight spray dried particles with two-thirds by weight canola oil)with good results. The resulting product had a mean particle size of 157microns.

Example 2

This example illustrates the production of a product of the presentinvention in which first encapsulant of the composition comprising thelabile compound is a biomass hydrolysate. The second encapsulant is aprill coating of hydrogenated canola wax.

Two pounds of dried biomass hydrolysate powder containing 22% DHA wereadded to molten, hydrogenated canola fat (Stable Flake—CN, Cargill) at100° C. to make a molten solution containing 25% biomass hydrolysate(5.5% DHA) at 80° C. The biomass hydrolyzate powder was produced inaccordance with the process generally described in U.S. patentapplication Ser. No. 11/433,752, filed on May 12, 2006, entitled BiomassHydrolysate and Uses and Production Thereof, which is incorporatedherein by reference.

The resultant solution was atomized using compressed air at 154° C. and45 psi into a prill tower using ambient air as the cooling air. Thepowder was collected and analyzed for particle size, solubility andsensory profile. The particle size of the original hydrolysate power was70.5 micron. The average particle size of the prills was 82.9 micron.The powder was found to be mostly water insoluble with improved,pleasant aroma and acceptable sensory profile.

Example 3

This example illustrates the stability of the products of the invention.Two samples were utilized. The product of the present invention is onein which composition comprising a labile compound is an algal oil andthe first encapsulant is formed by reacting a solution comprising aprotein, soy protein isolate, and a reducing sugar at a starting pH of10 to achieve a degree of protein hydrolysis of between about 1% andabout 15%, and combining the reacted solution with the algal oil, suchthat the reacted solution forms an encapsulant on the algal oil, andspray drying resulting mixture. This method is described in detail inU.S. provisional patent application Ser. No. 60/945,040, filed Jun. 19,2007, which is herein incorporated by reference in its entirety. Thesecond encapsulant is a prill coating of hydrogenated soy fat. Forcomparison purposes, the algal oil with a first encapsulant and nosecond encapsulant was used.

Product samples were stored at 40° C. to accelerate oxidativedegradation. They were evaluated weekly by trained sensory panelists inorder to detect oxidation products. Additionally, the samples weretested weekly by Gas Chromatography/Mass Spectrometry for staticheadspace of propanal and hexanal. Results are expressed as inductionperiod. Induction period for the sample was defined as the time when anaverage sensory score of 3.0 or greater first appeared (based on a 5point scale). Head space induction periods are defined as the time thereis a sharp increase (inflection point) in the concentration of volatileshexanal and propanal. Results are shown in FIG. 1. Sensory analysisindicates prilling of core material results in nearly an 8-fold increasein induction period (3 wks vs. 23 wks). Additionally, relative stabilityas determined by GC/MS indicates a 9-fold increase in shelf life (2 wksvs. 19 wks). Results such as these clearly underscore the additionalstability imparted as singly encapsulated product is prilled.

The foregoing description of the present invention has been presentedfor purposes of illustration and description. Furthermore, thedescription is not intended to limit the invention to the form disclosedherein. Consequently, variations and modifications commensurate with theabove teachings, and the skill or knowledge of the relevant art, arewithin the scope of the present invention. The embodiment describedhereinabove is further intended to explain the best mode known forpracticing the invention and to enable others skilled in the art toutilize the invention in such, or other, embodiments and with variousmodifications required by the particular applications or uses of thepresent invention. It is intended that the appended claims be construedto include alternative embodiments to the extent permitted by the priorart.

1. A product comprising: a composition comprising a labile compound; afirst encapsulant of the composition, wherein said first encapsulantforms a continuous or non-continuous coating on said composition, orwherein said first encapsulant is a matrix in which said labile compoundis entrapped; and a second encapsulant of the first encapsulant, whereinthe second encapsulant is a prill coating and comprises a Maillardreaction product, and wherein the product comprising said compositionand said first and second encapsulants is physically stable for at leastabout 30 days, and wherein said first encapsulant of said compositioncomprising said labile compound is a whole cell or a biomass hydrolysatederived from microorganisms.
 2. The product of claim 1, wherein thelabile compound is selected from the group consisting of apolyunsaturated fatty acid, a vitamin, a mineral, an antioxidant, ahormone, an amino acid, a protein, a carbohydrate, a coenzyme, a flavoragent, and mixtures of the foregoing.
 3. The product of claim 2, whereinthe labile compound comprises a polyunsaturated fatty acid from a sourceselected from the group consisting of a plant, an oilseed, amicroorganism, an animal, and mixtures of the foregoing.
 4. The productof claim 3, wherein the source is a plant selected from the groupconsisting of soybean, corn, safflower, sunflower, canola, flax, peanut,mustard, rapeseed, chickpea, cotton, lentil, white clover, olive, palm,borage, evening primose, linseed and tobacco and mixtures thereof. 5.The product of claim 4, wherein the plant is an oilseed plant.
 6. Theproduct of claim 5, wherein the source is the oilseed of an oilseedplant.
 7. The product of claim 3, wherein the source is a microorganismselected from the group consisting of Thraustochytriales,dinoflagellates, and Mortierella.
 8. The product of claim 3, wherein thesource is an animal selected from aquatic animals.
 9. The product ofclaim 2, wherein the labile compound comprises a polyunsaturated fattyacid having a chain length of at least 18 carbons.
 10. The product ofclaim 2, wherein the labile compound comprises a polyunsaturated fattyacid selected from the group consisting of docosahexaenoic acid, omega-3docosapentaenoic acid, omega-6 docosapentaenoic acid, arachidonic acid,eicosapentaenoic acid, stearidonic acid, linolenic acid, alpha linolenicacid (ALA), gamma linolenic acid (GLA), conjugated linolenic acid (CLA)and mixtures thereof.
 11. The product of claim 2, wherein the labilecompound comprises a vitamin selected from the group consisting ofVitamin A, Vitamin D, Vitamin E, Vitamin K, Vitamin B1, Vitamin B2,Vitamin B3, Vitamin B6, Vitamin C, Folic Acid, Vitamin B-12, Biotin,Vitamin B5 and mixtures thereof.
 12. The product of claim 2, wherein thelabile compound comprises a mineral selected from the group consistingof calcium, iron, iodine, magnesium, zinc, selenium, copper, manganese,chromium, molybdenum and mixtures thereof.
 13. The product of claim 2,wherein the labile compound comprises an antioxidant selected from thegroup consisting of lycopene, lutein, zeaxanthin, alpha-lipoic acid,coenzymeQ, beta-carotene and mixtures thereof.
 14. The product of claim2, wherein the labile compound comprises an amino acid selected from thegroup consisting of arginine, aspartic acid, carnitine, cysteine,glutamic acid, glutamine, glycine, histidine, isoleucine, leucine,lysine, methionine, phenylalanine, proline, serine, threonine,tryptophan, tyrosine, valine, SAM-e and mixtures thereof.
 15. Theproduct of claim 2, wherein the flavor agent comprises a flavor oil,oleoresin or mixtures thereof.
 16. The product of claim 1, wherein thefirst encapsulant of the composition comprising the labile compound is amicroorganism selected from the group consisting of Lactococcus lactis,Lactobacillus acidophilus, Lactobacillus crispatus, Lactobacillusamylovorous, Lactobacillus gallinarum, Lactobacillus gasseri,Lactobacillus johnsonii, Lactobacillus rhamnosus, Lactobacillus brevis,Lactobacillus fermentum, Lactobacillus plantarum, Lactobacillushelveticus, Lactobacillus casei, Lactobacillus delbruckii, Lactobacillusbulgaricus, Lactobacillus GG, Bifidobacterium bifidum, Bifidobacteriumbreve, Bilidobacterium infantis, Bifidobacterium longum, Streptococcusthermophilus and Leuconostoc mesenteroides.
 17. The product of claim 1,wherein the first encapsulant of the composition comprising the labilecompound is a dried whole cell.
 18. The product of claim 17, wherein thedried whole cell is a spray-dried whole cell.
 19. The product of claim1, wherein the first encapsulant is prepared by a method selected fromthe group consisting of fluid bed drying, drum (film) drying,coacervation, interfacial polymerization, fluid bed processing, pancoating, spray gelation, ribbon blending, spinning disk, centrifugalcoextrusion, inclusion complexation, emulsion stabilization, spraycoating, extrusion, liposome nanoencapsulation, supercritical fluidmicroencapsulation, suspension polymerization, cold dehydrationprocesses, spray chilling (prilling), and evaporative dispersionprocesses.
 20. The product of claim 1, wherein the prill coating isselected from the group consisting of a fatty acid monoglyceride; afatty acid diglyceride; a fatty acid triglyceride; a free fatty acid;tallow; lard; beeswax; lanolin; shell wax; insect wax; vegetable wax;carnauba wax; candelilla wax; bayberry wax; sugar cane wax; mineral wax;paraffin microcrystalline petroleum wax; ozocerite wax; ceresin wax;montan synthetic wax, low molecular weight polyolefin; polyol etheresters, sorbitol; Fischer-Tropsch process synthetic wax; rosin; balsam;shellac; stearylamide; ethylenebisstearylamide; hydrogenated castor oil;esters of pentaerythritol; mono and tetra esters of stearic acid;vegetable oil; a hydrogenated vegetable oil; and mixtures andderivatives of the foregoing.
 21. The product of claim 20, wherein theprill coating is a free fatty acid selected from the group consisting ofstearic acid, palmitic acid, and oleic acid.
 22. The product of claim20, wherein the tallow is selected from the group consisting of beeftallow, mutton tallow, pork tallow, and lamb tallow.
 23. The product ofclaim 20, wherein the hydrogenated vegetable oil is selected from thegroup consisting of hydrogenated cottonseed oil, hydrogenated sunfloweroil, hydrogenated safflower oil, hydrogenated soybean oil, hydrogenatedcorn oil, hydrogenated olive oil, hydrogenated canola oil, hydrogenatedlinseed oil, and hydrogenated flaxseed oil.
 24. The product of claim 1,wherein the Maillard reaction product is a reaction product of areducing sugar and a protein selected from the group consisting ofcasein, whey solids, whey protein isolate, soy protein, skim milkpowder, hydrolyzed casein, hydrolyzed whey protein, hydrolyzed soyprotein, non-fat milk solids, gelatin, zein, and albumin.
 25. Theproduct of claim 1, wherein the Maillard reaction product is a reactionproduct of a protein and a reducing sugar selected from the groupconsisting of fructose, glucose, glyceraldehyde, lactose, arabinose,maltodextrin, corn syrup solids and maltose.
 26. A product selected fromthe group consisting of a food product, a cosmetic product, apharmaceutical product, a nutraceutical product, a paint, a woodproduct, a textile, an adhesive, a sealant, a lubricant, leather, rope,paper pulp, a plastic, a fuel, oil, a rubber working fluid or a metalworking fluid, wherein the product comprises the product of claim
 1. 27.The product of claim 1, wherein the product is physically stable for atleast about 120 days.
 28. The product of claim 1, wherein the product isin a form selected from the group consisting of a free-flowing powder, abead, a chip, and a flake.
 29. A product selected from the groupconsisting of a food product, a cosmetic product, a pharmaceuticalproduct, a nutraceutical product, a paint, a wood product, a textile, anadhesive, a sealant, a lubricant, leather, rope, paper pulp, a plastic,a fuel, oil, a rubber working fluid or a metal working fluid, whereinthe product comprises the product of claim
 2. 30. The product of claim1, wherein said Maillard reaction product was formed by contacting thefirst encapsulant with the second encapsulant.
 31. The product of claim1, wherein said Maillard reaction product is at the interface of saidfirst and second encapsulants.
 32. The product of claim 1, wherein theproduct is in a form selected from the group consisting of afree-flowing powder, a bead, a chip, and a flake.
 33. The product ofclaim 1, wherein the Maillard reaction product was formed in anon-aqueous environment.
 34. A method for preparing a productcomprising: encapsulating a first encapsulated product in the presenceof an amino acid source and a reducing sugar to form a secondencapsulated product, whereby Maillard reaction products are formed inthe second encapsulant, and wherein the first encapsulated productcomprises an encapsulant of a labile compound, wherein said encapsulantof said labile compound forms a continuous or non-continuous coating onsaid compound, or wherein said first encapsulant is a matrix in whichsaid labile compound is entrapped, and wherein said first encapsulant ofthe composition comprising said labile compound is a whole cell or abiomass hydrolysate derived from microorganisms and wherein said secondencapsulant is a prill coating.
 35. The product of claim 1, wherein saidsecond encapsulant encapsulates a single discrete particle within asingle second encapsulant.
 36. The product of claim 1, wherein saidsecond encapsulant encapsulates a plurality of discrete particles withina single second encapsulant.
 37. The product of claim 1, wherein saidproduct comprises three to five encapsulants.
 38. The product of claim1, wherein said Maillard reaction product is found throughout saidsecond encapsulant.